Compressed air and chilled water £300k pa spend
Margins are tight due to tough competition
Focus on "right first time" across the business
Business output follows the building sector
Change management through benchmarking divisions and product materials
With annual energy costs of close to £3 million this plastics manufacturer faces considerable pressure to combat cost increases in rising energy markets. Management recognised the role of energy efficiency to improve market share in a very competitive environment. Optimised Energy was engaged for an initial period of 12 months to help identify and implement ways to improve energy efficiency through capital projects, data analytics and best practise.
As a major building plastics manufacturer with UK and Ireland multi-site presence serving global clients on tight timelines, energy efficiency is not always the highest concern. Capital projects must meet rigorous investment criteria, and they must not impact production operation or output in any way. The site has many manufacturing departments with shared energy infrastructure, varying priorities, but similar objectives in striving for operational excellence and profitability for the business.
Our engineers carried out an initial investment grade feasibility study to identify and quantify projects that met the Board’s investment criteria. Simultaneously, we harnessed real time energy data from a network of over 100 sub-meters, which was combined with department specific production metrics and published onto a custom dashboard. We then worked with our network of technology specialists to draft detailed project specifications, carry out competitive tenders, and work with contractors to deliver solutions.
The output of our analysis and project identification has resulted in the delivery of 9 projects within 6 months, and a savings projection for 12 months of £75,000. All projects are measured and verified according to International Performance Measurement and Verification Protocol (IPMVP). The site now has full visibility of its energy costs at department and system level, as well as robust insight as to what drives performance. Departments are now working to challenging efficiency targets.
"With a new, robust energy management system, our integrated approach to procurement, compliance and energy efficiency has cut costs and reduced risk".
Energy usually accounts for anything from 1% to 20% of our clients’ cost base. This means that the organisations tend to be at different stages along their energy journey. We adapt our approach to suit companies that are seeking to identify the challenge, right through to those that have invested heavily in energy efficiency for the last two decades. Our team brings many years of experience combined with a proven approach to delivering outcomes through strategy, consulting and outsourcing activities.
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